Here is a shot of the hardcopy in its disassembled state. Kenner employed metal dowels to hold their hardcopies together. You'll notice James also has one lower leg to match the torso. The pieces are cast in a green urethane, commonly referred to as "dynacast". This material was prominently used for hardcopies during the mid-80's.
Hardcopies are produced using a silicon mold (this mold is created from the orginal wax figure sculpting). Once the hardcopy is removed from the mold it may serve a number of purposes. It might remain unpainted and ultimately used to create the steel tooling for the figures. Extra hardcopies are poured as a precaution, should something happen to the tooling master. These extras would remain unpainted as well. If a hardcopy is not destined for tooling or backup, then it will more than likely be handpainted for use in catalog photography, trade shows, or as a paintmaster.
Special thanks go to James Gallo for allowing me to photograph this wonderful unproduced prototype. If you are looking for a specific toy, you can email James at jgallony@aol.com or call his store, Toy Heaven, at 610-649-8161. He has a wonderful reputation in the hobby and an incredible inventory of 70's, 80's, and current toys.
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